Triangle SR12 User's Manual
Contents
1. the rate at which vapor is capable of passing up the column against resistance of the packing it is a measure of the output capacity of the still Page 162. according to the top bulb thermometer before the distilling chamber cover is opened Opening the cover at a higher temperature will release solvent fumes into the surrounding air and can also cause burn injury to the operator NOTE Opening the cover sooner than one hour after the distillation cycle has finished wil cause the cover gasket to swell Page 6 OPERATING PROCEDURES Purpose The TBS Solvent Recovery System was manufactured for the purpose of recovering solvents used within the laboratory setting Many laboratories now use the TBS equipment for recovering solvents such as xylene and graded alcohols See List of Acceptable Distillation Solvents in this manual In the average size laboratory the recovery of these two solvents have proven to have saved thousands of dollars each year as well as protecting the environment from toxic chemicals being stored and or transported In addition laboratories have decreased their cost of hauling hazardous waste off sight as well as the undesirable regulatory responsibilities that go along with that waste removal NOTE When handling chemicals use gloves safety glasses with splash guard and an apron Procedure for Recovering Alcohol 1 Place clean and dry collection containers under each of the lower distillate solvent outlet nozzles left and right 2 Verify that the Thermal oil level is at the correct level 3 Place the disposable plastic bag into the vessel using the expanda
3. collecting duct Be sure that the distilling chamber remains free of liquid and debris after each cycle Approximately 45 90 minutes are necessary before the distillate begins to flow Be certain that there is sufficient ventilation to prevent dangerous gases and vapors from forming During the first few distillation cycles there may be a small amount of thermal oil leakage This is quite normal and is to be expected Do not tilt or shake the unit once loaded or when operating This could create a dangerous situation Page 9 IMPORTANT IF CHLORINATED SOLVENTS ARE TO BE RECOVERED YOU MUST USE THE WORKING TEMPERATURES GIVEN IN THE ACCEPTABLE DISTILLATION SOLVENTS TABLE WORKING WITH A HIGHER TEMPERATURE COULD RESULT IN FORMATION OF HYDROCHLORIC ACID THIS CHEMICAL REACTION COULD CAUSE DAMAGE TO BOTH THE VESSEL AS WELL AS THE CONDENSER BOTH MADE OUT OF STAINLESS STEEL THIS WOULD VOID ANY AND ALL WARRANTIES ACCEPTABLE DISTILLATION SOLVENTS Flammable Solvents Boiling Ignition Name Point C Point C Acetone 50 535 Benzol 80 560 2 Butanol 118 366 N Butyl Acetate 128 370 N Butyl Alcohol 118 366 Butyl Cellosove 173 239 N Butyl Ether 143 185 Cellosolve 143 235 Cellosolve Acetate 156 377 Cyclohexane 81 260 Cyclohexanon 155 419 1 2 DiChlorethane 84 412 DiEthyl Cellosolve 121 208 DiEthyl Ketone 104 445 Ethanol 82 400 Ethyl Acetate 79 427 Ethyl Amyl Keytone EAK 160 Ethylene Glycol 198 413 2 Puran Methanol 162 490 N Hexan
4. will not be effected and the unit will not be damaged if you over set the timer NOTE When you wish to recycle alcohol boiling point of 78 C it is necessary to change the temperature of Page 7 the Working Thermostat dial setting The setting should be reduced to 150 C the same for Alcohol and you must adjust the Fractional Thermostat temperature down to 85 C when recovering Alcohol 9 The first container under the solvent outlet nozzle will collect the purest alcohol Your second container under solvent outlet nozzle will collect the recovered alcohol 10 After a recovery cycle has been completed let the unit cool to at least 50 C prior to opening the secured top Premature opening will allow a release of solvent fumes into the surrounding atmosphere and can also cause burn injury to the operator 11 Open the cover remove expandable ring and disposable bag Dispose of the waste in the bag according to appropriate state and local guidelines NOTE Take special care not to spill any remaining waste material especially wax into the vapor collecting duct 12 Be sure that the distilling chamber remains free of liquid and debris after each cycle Approximately 45 90 minutes are necessary before the distillate begins to flow Be certain that there is sufficient ventilation to prevent dangerous gases and vapors from forming During the first few distillation cycles there may be a small amount of thermal oil leakage This is quite no
5. 0 357401 427000 427001 NG20001 NG20002 Description Cover Gasket Ether Cover Gasket Ether Cover Gasket Xylene Cover Gasket Xylene Condenser Steel Condenser Steel Warning Light Socket Safety Thermostat T3 Working Thermostat T1 Safety Thermostat T2 White Warning Light Red Warning Light Green Warning Light Ventilator Motor Heating Element Timer Control Knob Bushing for Spring Locking Stay Bushing for Spring Locking Stay Spring for Stay Spring for Stay Stay Stay Hand Wheel Hand Wheel Three way Fraction Valve Expl Proof Fraction Outlet Nozzle Page 15 12 liter RA St A SSS Se STATS 19 Liter Se SS So SS SEAS AR ARAS ee GLOSSARY Auto ignition Point The temperature at which a solvent will self ignite no stimulus required Baffle A metal duct used to direct the vapors to the vapor collection manifold The baffle is filled with packing to impede the flow of vapor causing a reflux The condensed liquid rectifies vapor Boiling Point The temperature at which the given product starts to transform into its gaseous form Cut A fraction or portion of distilled material taken off at the head Vapor Collection Duct Manifold of the still Distilland The mixture of materials placed in the distilling vessel the material to be distilled Distillate The material that has been boiled through a column The separated material taken off at the head Efficiency A means of comp
6. 1 X 76 X 173 cm Weight 74 kg 135 kg LIST OF PARTS 24 Locking Knob 1 Distilling Chamber 25 Cover Gasket 2 Camber Cover 26 Arm for Cover 3 Electrical Box Cover Expl Prf 27 Vapor Collector Duct Manifold 4 Electric Box Housing Expl Prf 28 Solvent Outlet Nozzle Left 5 Bushing Carrier Expl Prf 29 Solvent Outlet Nozzle Right 6 Fraction Switch Cable 30 Oil Temperature Gauge 7 Electrical Heating Element s 31 Oil 8 Thermal Oil Vessel 32 Bag Holder Max Level of Solvent 9 Fan Motor Junction Box Expl Prf 33 Main Power Electric Cable 10 Distilling Condenser 34 Motor Cable Sheath Pipe Expl Prf 11 Cooling Fan Motor Expl Proof 35 Unit Support 12 3 Way Fraction Switch Expl Prf 36 Shell 13 Heater Cable Sheath Pipe Expl Prf 37 Heater On Indicator Orange 14 Solvent Receiver Tanks 38 Main Power Indicator Green 15 Solvent 39 Alarm Indicator Light Red 16 Oil Discharge 40 Timer Module 17 Thermal Oil Level Indicator 41 Working Thermostat T 1 18 Working Thermostat T 1 42 Safety Thermostat T 2 19 Timer 43 Safety Thermostat T 3 20 Fraction Thermostat T 4 44 Fraction Thermostat T 4 21 Indicator Window 45 Safety Relay 22 Vapor Temperature Gauge 46 Heater Power Relay 23 Oil Bleeding Valve 47 Fraction Switch Junction Box Page 14 SPARE PARTS Code 239004 239010 382000 382001 384007 384008 384009 384010 465000 465001 465002 475000 468402 385007 425002 350901 350911 353702 428001 35740
7. 4 9393 CONDITION OF RETURNED EQUIPMENT Before returning equipment to TBS you must contact TBS or your dealer and receive a return good authorization All returned units must be cleaned and decontaminated The RGA paperwork includes a Certificate of Decontamination for you to sign indicating that you have performed these steps TBS will not accept the shipment until this signed certificate is received You must prepay transportation to the service depot In addition TBS must receive unit packed and shipped in compliance with our shipping crating instructions Failure to properly crate and ship the unit could result in additional repair fees Page 4 GENERAL INFORMATION The TBS Solvent Recovery System is designed for recovering solvents used in Histopathology with a boiling point between 50 180 C Using a closed system with fractional distillation design the Solvent Recovery System can be operated simply and safely This Manual Reading this manual is essential for correct and safe use of this equipment Application The TBS Solvent Recovery System will successfully and economically recover most solvents used for dehydration extraction of fat and as an inter medium Xylene acetone ethanol toluene etc Function The waste solvents distilland from tissue processors and or tissue stainers are heated inside the distillation vessel of the recycler converted to vapor and then condensed back into a liquid A thermostat and a t
8. General TBS Solvent Recovery Systems adhere to ETL guidelines for safety and manufacturing It is suggested that your laboratory purchase an appropriate fire extinguisher to be placed within ten feet of any electrically heated equipment TBS recommends that the Safety Officer for your facility be contacted for proper storage and disposal of any hazardous substance being recycled Location It will be necessary for to contact the Environmental health and Safety Officer and the local fire marshal regarding placement recommendations for your Solvent Recovery System Page 5 TBS Solvent Recovery Systems have been designed and manufactured to be ignition resistant if operated in a highly volatile environment explosion proof All units are shipped with a normal 15 amp Hospital Grade ETL amp UL approved electrical plug Be advised that if you intend to operated your unit in a dangerously volatile environment an explosion proof plug must be installed with its special receptacle Solvent Containment TBS offers a stainless steel splash pan designed for your equipment to be placed on the floor under your recovery unit This pan is recommended for use as a safety pan to prevent solvents from spilling onto the floors in case of an over flow due to operator error Appropriate 3 gal containers for the collection of recycled solvents and run off waste are available from TBS Safe Exposure Temperature The temperature should be at 50 C or below
9. Operation And Service Manual SR12 Version 1 2 Serial IBS TRIANGLE BIOMEDICAL SCIENCES INC 3014 CROASDAILE DRIVE e DURHAM NORTH CAROLINA 27785 e 919 584 9595 e FAX 919 584 9595 e E MAIL info trianglebiomedical com TABLE of CONTENTS POWARD ts SN A A 3 WARRANT Y et seele ea 3 EXTENDED WARRANTS idas 3 CONDITIONS OB RETURN it euere 3 GENERAL INFORMATION 2 2 ae 4 PDC OA ac 4 F ncton eie enne 4 Separaton M O dU Sd A a aiGendte 4 Salety Meas rerS A AS A E enc 4 OPERATIONAL SA E a tata onda Maa RN 4 O 4 Solvent COMA AA SAA 4 Safe Exposure Femperalure A A as 5 OPERATING PROCEDURES ai ie 6 LUPO eye A A A aaa 6 Procedure Tor O taa 6 POCERO ae 7 ACCEPTABLE DISTILLATION SOLVENTS ia asas 9 HAMAS entes dal ela 9 No flammable Solvents iii 10 MAINTENANCE a a A A AR 10 Weck NO 10 A see 10 BARB TY BEA LURES A BER messen 11 MALFUNCTIONS CAUSES AND REMEDIES ssursssaosssssossssnnsensnnssssnssssonsessnnstssnnee 12 TECHNICAL DATA seen a 13 ESTOPA RES 5 A A a a a ane 13 SPARE PAIR TS ee A A 14 Page 2 Page 3 FOREWORD This manual is designed to exhibit the information needed for installing operating and troubleshooting the TRIANGLE BIOMEDICAL SCIENCES INC SR 12 SOLVENT RECOVERY SYSTEM The SOLVENT RECOVERY SYSTEM is specifically designed to recycle Alcohol and Xylene The user may need to manage the concentration of the contaminated solvent to ensure a higher percentage of recycled solvent WA
10. RRANTY TRIANGLE BIOMEDICAL SCIENCES INC TBS for itself and all its subsidiaries does hereby warrant for a period of one year 12 months from the date of shipping under normal and proper usage all of its products against defects in workmanship and material and will repair or replace the same without charge when shipped prepaid to TBS s factory in Durham NC USA If the product cannot be so shipped except for parts and accessories there will be a charge for all expenses incurred for repairing or replacing the product on the user s premises Parts and accessories manufactured or supplied by others are warranted only under the regular warranty of the manufacturer or supplier of such parts in so far as TBS or its subsidiaries are able to transfer the benefit of such warranties to the user This warranty supersedes and is given in lieu of all implied warranties and is void 1f user does not provide unit with continuous ample electrical power at constant voltage consistent with the specifications of the product User is required to return the warranty card to TBS within ten 10 days after receipt of the product in order to validate the warranty EXTENDED WARRANTY Triangle Biomedical Sciences Inc has available an Extended Warranty Agreement which will provide an extension or the warranty for a 12 month period on parts and labor for preventive maintenance and repairs For details and costs please contact the TBS office at 1 919 38
11. aring the actual useful separating power of distillation columns Flash Point The temperature at which the solvent will ignite if brought in contact with a spark Flooding Excess liquid forced up the still into the condenser as a result of overfilling the vessel and the high heat input at the pot Usually detrimental since the distlland mixture is forced into the area in which only pure material is desired Fraction A portion of the collected separated material recovered from the head of the still Fractional Distillation distillation in which rectification is used to obtain a product as nearly pure as possible In the operation part of the vapor is condensed as it passes through packing and the liquid is refluxed down the column thus producing a high vapor to liquid contact The term is also used to describe any distillation in which the product is collected in a series of fractions or cuts Rectification The enrichment or purification of vapor by contact and interaction with a counter current stream of liquid condensed from the vapor Reflux the term used to describe the liquid condensed from rising vapor which is allowed to flow back down the column Simple Distillation Distillation in which no appreciable rectification or reflux occurs All condensed vapor is removed from the still at the head Takeoff the liquid removed from the still per unit time The amount of separated material recovered from the still Throughput
12. ble metal ring to hold the bag in place Note For the 3 gal unit small hole should be cut near the top edge of the bag to fit over the vapor collection duct 4 Place the contaminated solvent in the distilling chamber up to 3 gallons NOTE Take special care NOT to allow any contaminated solvent to enter the Vapor Collector Duct Manifold when you are filling the distilling chamber This may create a build up of wax inside of the condensing coils that can cause blockage and unwanted pressure within the distilling chamber during recovery 5 Close the cover of the chamber by securing the locking knob by tighten clockwise until the knob stops The spring will act as a release valve if an unlikely blockage of the vapor collector duct occurs 6 Set the distillation temperature with the Working Thermostat 15 C above the boiling point of the contaminated solvent to be recovered 7 Setting of the fractional temperature depends on the solvent you are recycling You should then set the fractional temperature at approximately 20 30 C higher than your highest boiling point of the contaminates Alcohol has a boiling point of 78 Your fractional temperature switch will be set at a minimum of 85 C for the recovery of alcohol 8 Set the timer for distillation For a full distilling chamber it will take 5 6 hours for complete distillation to be accomplished This may vary with the solvent Alcohol for example may take up to 6 hours The final results
13. e 70 240 Kerosene 190 259 210 Isobutyl Acetate 119 420 Isobutyl alcohol 111 430 Isopropanol 83 400 Isopropyl Acetate 89 460 Methyl Ethyl Ketone M E K 80 530 Methyl Acetate 58 475 Methyl Amyl Ketone 150 311 Methyl Cellosolve 124 285 Methyl Cellosolve Acetate 156 377 Methyl Isobutyl Ketone M I B K 117 459 Mineral Spirit 1 162 180 250 Mineral Spirit 2 185 215 N Octane 126 220 N Propanol 98 213 S B A Sec Butanol 101 Shellosol TD Isopar H Sepisol TD Helpasol 170 195 170 187 Shellsol T Isopar L Sepisol T Halpasol 180 185 180 214 Shellsol D40 Exol D40 Sepisol D40 162 197 Shellsol HD60 Exxol D60 Sepisol HD60 185 219 Page 10 Shellsol D70 Exxol D80 Sepisol KD70 190 257 Shellsol A Solvesso 100 Sepisol A 162 180 Shellsol AB Solvesso 150 182 215 Shellsol H Varsol 60 Sepisol H 180 210 Toluene Toulol 111 535 Turpentine Gum Spirits 152 270 250 Xylol Xylene 140 525 IMPORTANT INFORMATION Never open the recycler prior to the suggested cool of time of 50 C Always be certain that the cover gasket does not show signs of wear or have any debris attached to it The green on light should be indicated prior to starting each cycle WARNING Never change the thermal oil before allowing the machine to cool for at least 48 hours Nonflammable Solvents Boiling Working Name Point C Temp CC Chloroform Trichloromethane 661 90 Methilene Chloride DiChlormethane 40 70 Freon 113 Frigen 113 46 80 Carbon Tetrachloride T
14. e stopped and the red indicator light will be activated Fractional Thermostat A probe monitors the temperature of the vapor at the vapor collector duct The Fractional Thermostat allows the operator the ability to control the temperature when the three way valve will switch the distillate from the left distilled outlet nozzle to the right distilled outlet nozzle The red indicator light out of work signals that one of the safety thermostats have intervened Turn off the apparatus and refer to the Malfunction Causes and Remedies portion of this manual Page 12 MALFUNCTIONS CAUSES AND REMEDIES Problem Unit is heating up to set temps Unit will recycle off water alcohol and xylene into one container second container first container remains empty Initial troubleshooting revealed that the switching module was okay and did not need replaced Possible Solutions Middle thermostat which controls distillation temp may have become loose within well and is not registering temp Middle Thermostat may need replaced To Check Turn unit on heat it without anything in it Move the middle thermostat back and slowly move to higher temp Watch to see if the indicator light changes from set to distillation temp If this happens thermostat is okay Thermostat probe may still be out or loose in distillation chamber Take front cover off of unit it comes in on the top right side of the unit Distillation time lasts much Conta
15. etrachloromethane 78 110 1 1 2 2 Tetrachloroethane Acetylene Tetrachloride 147 160 Tetrachloroethylene Pestabil Vors Perchloroethylene Per 121 150 Trichloroethane 1 1 1 3 1 Chlorothene Genklene Solvetane Baltane Mecloran 74 110 Tricholoethylene Tri Vorclin Althene Triklone 87 120 Warnings 1 When treating nonflammable solvents do not set the working thermostat at a temperature higher than that shown above Higher temperatures may produce hydrochloric acid acidify the solvent and consequently damage the recycler 2 Any solvent containing more than 35 water will not recycle successfully MAINTENANCE Daily A Clean the distillation vessel remainder of 8 1 from Omega Manual B it is best to remove paraffin build up when the unit is warm Weekly A Using a soft cloth and mild solvent clean up the exterior of the apparatus C Check the thermal oil level when the unit is cold the level should be at the lower indicator Page 11 NOTE Because the oil expands when it is heated leakage will occur if the oil reservoir is over filled Annual After 2 000 hours of operation of the 3 gal unit or after one year which ever is earlier it will be necessary to have preventive maintenance performed on the unit This annual maintenance will include a change of the thermal oil and servicing of various other parts along with the extension of the limited warranty for an additional 12 months This can be accomplished by either 1 purc
16. hasing an Extended Warranty Agreement or 2 for a fee having a technician from the laboratory trained and certified to perform the maintenance SAFETY FEATURES The red indicator light when illuminated indicates that one of the two Safety thermostats has completely turned off the system at sometime during the recovery cycle The following is a description of all four thermostat and timer Only Safety thermostats will activate the red indicator light Timer Basic five hour timer Rotate clockwise to start the recovery cycle Note that the cooling fan will continue to operate for 30 minutes after the heating cycle has ended Working Thermostat Used to control the temperature of the thermal oil that transfers heat to the distilling chamber Range 40 200 C Note The oil temperature is generally 15 20 C higher than the temperature of the contaminated solvent within the distilling chamber Safety Thermostat Monitors the temperature of the thermal oil If the Working Thermostat should malfunction Safety Thermostat will STOP the heating if the oil temperature to exceed exceeds 225 C The red indicator Light will be activated Safety Thermostat The cooling fan cools the distillate to a temperature slightly above room temperature Should the fan malfunction the distillate pouring out of the outlet nozzles will be hot The Safety Thermostat monitors the temperature of the distillate If that temperature exceeds 40 C the electrical heating will b
17. imer will control the process The vaporized solvent is directed through a collection pipe to an air cooled distilling condenser where the vapor is condensed back into liquid The distillate is then collected in a closed container on the outside of the unit The recovery rate of the solvent will depend on the grade of contamination of the waste solvent being recycled Separation Module The TBS Solvent Recovery System utilizes the principle of Simple Distillation however 1t will achieve the results of Fractional Distillation using the Separation Module and Baffle The Switching Module allows an operator to set a fraction temperature at which the distillate of the different solvents will be separated The fraction temperature is set relative to the boiling point of the solvent you wish to recover This fraction temperature is easily set at the beginning of each recovery cycle Safety Measures TBS Solvent Recovery Systems work ONLY with atmospheric pressure Should the thermal oil temperature exceed the maximum set value of the working thermostat by more than 25 C or if a defective cooling fan allows the distillate to emerge at a temperature higher than 40 C 104 F the distillation process will be interrupted by a complete and total shut down of the unit The unit will shutdown if the Thermal Oil temperature exceeds 225 C TBS solvent Recovery Systems have been extensively tested and approved by the ETL Testing Laboratories OPERATIONAL SAFETY
18. ing point of the contaminates Alcohol has a boiling point of 78 Your fractional temperature switch will be set at a minimum of 85 C for the recovery of alcohol Page 8 10 11 12 Set the timer for distillation For a full distilling chamber it will take 5 6 hours for complete distillation to be accomplished This may vary with the solvent Alcohol for example may take up to 6 hours The final results will not be effected and the unit will not be damaged if you over set the timer NOTE When you wish to recycle alcohol boiling point of 78 C it is necessary to change the temperature of the Working Thermostat dial setting The setting should be reduced to 150 C the same for Alcohol and you must adjust the Fractional Thermostat temperature down to 85 C when recovering Alcohol The first container under the solvent outlet nozzle will collect the purest alcohol Your second container under solvent outlet nozzle will collect the recovered alcohol After a recovery cycle has been completed let the unit cool to at least 50 C prior to opening the secured top Premature opening will allow a release of solvent fumes into the surrounding atmosphere and can also cause burn injury to the operator Open the cover remove expandable ring and disposable bag Dispose of the waste in the bag according to appropriate state and local guidelines NOTE Take special care not to spill any remaining waste material especially wax into the vapor
19. minated solvent Replace the solvent longer than 4 hours contains too much water Add oil Thermal oil level is low 2 Change the oil Thermal oil is old and Remove and clean with dirty solvent Heating elements need cleaning Heats but does not distill Distilling chamber is dirty 1 Clean chamber Solvent distillation temp is 2 Increase the Working higher than set on working Thermostat temp setting thermostat 3 Change solvent Distillate temperature too high 4 Add oil Thermal oil level is low Red Indicator Light is ON Working temperature is too 1 Reduce the working temp high 2 Change the Working The max temp Safety Thermostat Thermostat intervened Replace motor The distillate Safety Clean or replace Thermostat intervened Remove the protective cage Cooling motor not operating and clean it with a brush or air Distilling Condenser scaled pressure Maximum Temp Safety 6 Replace Max Temp Safety Thermostat is defective or out Thermostat of calibration Condensing apparatus has Page 13 CC become clogged with dirt AAA TECHNICAL DATA Maximum Capacity 12 Liters 3 2 gal 19 Liters 5 0 gal Type of Distillation Simple Simple Volume of Thermal Oil 5 Liters 1 5 gal 14 Liters 4 0 gal Voltage 115V 60Hz 115V 60Hz Current 9 Amps 17 5 Amps Working Temperature 40 200 C 424 F 40 200 C 424 F Cycle Time 5 6 Hours 5 6 Hours Condenser Air Cooled Air Cooled Size W x D x H 59 X 59 X 145 cm 6
20. rmal and is to be expected Do not tilt or shake the unit once loaded or when operating This could create a dangerous situation Xylene 1 Place clean and dry collection containers under each of the lower distillate solvent outlet nozzles left and right 2 Verify that the Thermal oil level is at the correct level 3 Place the disposable plastic bag into the vessel using the expandable metal ring to hold the bag in place Note For the 3 gal unit small hole should be cut near the top edge of the bag to fit over the vapor collection duct 4 Place the contaminated solvent in the distilling chamber up to 3 gallons NOTE Take special care NOT to allow any contaminated solvent to enter the Vapor Collector Duct Manifold when you are filling the distilling chamber This may create a build up of wax inside of the condensing coils that can cause blockage and unwanted pressure within the distilling chamber during recovery 5 Close the cover of the chamber by securing the locking knob by tighten clockwise until the knob stops The spring will act as a release valve if an unlikely blockage of the vapor collector duct occurs 6 Set the distillation temperature with the Working Thermostat 15 C above the boiling point of the contaminated solvent to be recovered 7 Setting of the fractional temperature depends on the solvent you are recycling You should then set the fractional temperature at approximately 20 30 C higher than your highest boil
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